Connector assemblies for connecting panels

ABSTRACT

In one embodiment, a connector assembly comprises: a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

TECHNICAL FIELD

The present disclosure generally relates to connectors and collectorsfor connecting panels.

BACKGROUND

In the construction of naturally lit structures, such as greenhouses,pool enclosures, solar roof collectors (e.g., photovoltaic modules),stadiums and sunrooms, glass panel roofs have been employed to allownatural light to shine therein. The glass panels themselves can bemounted in frame-like enclosures that are capable of providing awatertight seal around the glass panel and provide a means for securingthe panel to a structure. These frame-like enclosures also provide formodular glass roofing systems that can be assembled together to form theroof.

Glass panel roofing systems generally provide good light transmissionand versatility. However, the initial and subsequent costs associatedwith these systems limits their application and overall marketacceptance. The initial expenses associated with glass panel roofingsystems comprise the cost of the glass panels themselves as well as thecost of the structure, or structural reinforcements, that are employedto support the high weight of the glass. After these initial expenses,operating costs associated with the inherently poor insulating abilityof the glass panels can result in higher heating expenses for the owner.Yet further, glass panels are susceptible to damage caused by impact orshifts in the support structure (e.g., settling), which can result inhigh maintenance costs. This is especially concerning for horticulturalapplications wherein profit margins for greenhouses can be substantiallyimpacted due to these expenditures.

As a result, multiwall polymeric panels (e.g., polycarbonate) have beenproduced that exhibit improved impact resistance, ductility, insulativeproperties, and comprise less weight than comparatively sized glasspanels. As a result, these characteristics reduce operational andmaintenance expenses. Polymeric panels can also be formed as solidpanels. Solid panels are solid plastic between their front and rearfaces, and are useful where high impact resistance, high clarity, and/orthe ability to thermoform the panel is desired. Multiwall panels havevoids between their front and rear faces, e.g., the panel may beextruded as a honeycomb with an array of passages extending along theextruded length of the panel. Multiwall panels are useful where a highinsulation value, lightweight, and easy installation, are desired.

For ease of design and assembly, multiwall panels can be produced inmodular systems. The modular systems comprise multiwall panels withintegral panel connectors, wherein the panel connector assemblies areemployed to join the panels together and/or secure the panels to astructure on which they are employed. Standard panels can also be used,which are formed continuously and uniformly, i.e., they are extrudedslabs and are cut to size and installed in the same manner as glass.These standard panels require a frame or the like to hold them in place.

Modular panels are advantageous for their extreme ease of installation,but are disadvantageous owing to their limited versatility in thatmodular panels cannot be cut to a desired size if such cutting involvesloss of a connecting edge, because the modular panel will no longer bereadily connectable to other panels at the cut edge. As a result, if apanel with an unusual or non-standard width is desired, a new extrusiondie must be commissioned, at great expense, so as to be able to extrudepanels of the desired width, and having the desired connecting edges.Further, modular panels are naturally limited to use with modular panelshaving complementary attachment structure (i.e., a tongue-and-groovepanel will connect to other tongue-and-groove panels having the sametongue/groove configuration, but will not connect to standing seampanels). Standing seam generally refers to a panel with an integratedside collector adjoined to another panel with the use of a connectionsystem. Thus, greater flexibility in the size of the modular panels,without the requirement for expensive equipment and retooling, and theability to connect to a variety of panels is desired.

Additionally, modular panels can be subject to high wind loads dependingupon the structure and location on which they are installed, and must beable to withstand certain live loads (e.g., wind loads) and static loads(e.g., snow loads) in order to satisfy various building codes (e.g., beable to support 3 feet (0.9 meter) of wet snow and/or be able towithstand wind loads of 80 miles per hour (mph) to 280 mph (130kilometers per hour (kph) to 450 kph)). Wind loads can create negativeforces which can pull a modular panel off its supports and thus, lead topremature failure of the modular panel. An improved connector assemblythat can withstand high wind loads and not allow a panel to be pulledfrom its supports is continually desired.

BRIEF DESCRIPTION

Disclosed, in various embodiments, are side collectors and connectorassemblies comprising a clip and methods for connecting panels with theside collectors and/or connector assemblies comprising clips, and panelsusing the side collectors and/or connector assemblies comprising clips.

In one embodiment, a connector assembly comprises: a connector; and apair of side collectors, each comprising a connector engagement regionhaving a size and geometry to mate with the connector so as to hold endsof two adjacent panels together; and a panel engagement regioncomprising a receiving area and having a size to attach onto an edge ofthe panel; and a clip, wherein the clip has a base that can be attachedto a support, an engagement, and a stem extending therebetween, whereinthe engagement has an extension projecting from a side of theengagement, wherein the panel engagement region further comprises anopening in a joint wall on a side of the panel engagement regionopposite the receiving area, wherein the opening is configured toreceive the extension of the engagement.

In one embodiment, a side collector comprises: a connector engagementregion comprising a head having a size and geometry to mate with a panelconnector; a panel engagement region comprising a receiving area havingan energy director extending into the receiving area, and having a sizeto attach onto an end of the panel; and a clip engagement regioncomprising an opening, and having a size to accommodate an extension ona side of an engagement of a clip.

In one embodiment, a panel assembly comprises: a connector assembly,comprising a connector; a pair of side collectors, each comprising aconnector engagement region; and a panel engagement region comprising areceiving area; and a clip, wherein the clip has a base that can beattached to a support, an engagement, and a stem extending therebetween,wherein the engagement has an extension protruding from a side of theclip, wherein the panel engagement region further comprises an openingin a joint wall on a side of the panel engagement region opposite thereceiving area, wherein the opening is configured to receive theextension of the engagement; a panel located in each panel engagementregion; and wherein the connector is mated with the connector engagementregion of the side collectors so as to hold ends of the panels together.

In one embodiment, a method of making a panel assembly, comprises:attaching a first panel to a second panel with a connector assembly,wherein the connector assembly comprises a connector; and a pair of sidecollectors, each comprising a connector engagement region having a sizeand geometry to mate with the connector so as to hold ends of twoadjacent panels together; and a panel engagement region comprising areceiving area and having a size to attach onto an edge of the panel;and a clip, wherein the clip has a base that can be attached to asupport, an engagement, and a stem extending therebetween, wherein theengagement has an extension projecting from a side of the engagement,wherein the panel engagement region further comprises an opening in ajoint wall on a side of the panel engagement region opposite thereceiving area, wherein the opening is configured to receive theextension of the engagement.

In one embodiment, a method of making a photovoltaic module assemblycomprises: attaching a first photovoltaic module to a secondphotovoltaic module with a connector assembly, wherein the connectorassembly comprises a connector; and a pair of side collectors, eachcomprising a connector engagement region having a size and geometry tomate with the connector so as to hold ends of two adjacent panelstogether; and a panel engagement region comprising a receiving area andhaving a size to attach onto an edge of the panel; and a clip, whereinthe clip has a base that can be attached to a support, an engagement,and a stem extending therebetween, wherein the engagement has anextension projecting from a side of the engagement, wherein the panelengagement region further comprises an opening in a joint wall on a sideof the panel engagement region opposite the receiving area, wherein theopening is configured to receive the extension of the engagement.

In one embodiment, an assembly comprises: a connector comprising twocavities defined by flexible walls, wherein each of the cavities has ageometry and is configured to mate with connector engagement regionsfrom a pair of side collectors; a header located between the twocavities; and a first slot on a side of the connector and between thecavities, wherein the first slot has a size and geometry to receive anend of a panel without a side collector, wherein the cavities enable twosets of panels to be stacked and connected with the connector; and aclip, wherein the clip has a base that can be attached to a support, anengagement, and a stem extending therebetween, wherein the stem divergesto a receiver located on an end of the stem opposite the base, whereinthe engagement has an extension projecting from a side of theengagement, wherein a panel engagement region on the side collectorscomprises an opening in a joint wall on a side of the panel engagementregion opposite a receiving area, wherein the opening is configured toreceive the extension of the engagement.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings, which arepresented for the purposes of illustrating the exemplary embodimentsdisclosed herein and not for the purposes of limiting the same. It isnoted that various elements of the embodiments are interchangeable withother embodiments as long as collectors and if used, clip, are mateableand/or, for side seams, the connector and associated collectors, and ifused, clip, are mateable, as would be readily understood. However, forsimplicity, not every single combination has been illustrated.

FIG. 1 is a front view of a clip for use in assembling a structure.

FIG. 2 is a cross-sectional end view of a panel with an integrated sidecollector.

FIG. 3 is a front view of a connector for use in assembling a structure.

FIG. 4 is a front view of FIG. 1 to FIG. 3 assembled.

FIG. 5 is a front view of various designs for the clip of FIG. 1 alongline A-A.

FIG. 6 is a front view of another embodiment of a clip for use inassembling a structure.

FIG. 7 is a front view of a design of a clip for use in assembling astructure.

FIG. 8 is a front view of a standing seam side collector with a spacerbetween collector halves.

FIG. 9 is a side view of a standing seam side collector with extensionshaving energy directors and a panel to be connected thereto.

FIG. 10 is a front view of an assembled connector and side collectorswith a thermal expansion clearance and with the clip of FIG. 6 havingprotrusions that attach to the panel.

FIG. 11 is an isometric view of a clip having a lip to hold an assemblytogether when exposed to a load.

FIG. 12 is a side view of a standing seam side collector with extensionshaving energy directors and a panel to be connected thereto and a cliphaving the design of FIG. 11.

FIG. 13 shows the assembly of FIG. 12 when a negative load is applied.

FIG. 14 is a cross-sectional view of a panel having allowance for theclip design of FIG. 11.

FIG. 15 is a cross-sectional view of a lap joint connection system witha mating area for receiving the clip having the design of FIG. 11.

FIG. 16 is a front view of a double-sided connector with slots forreceiving additional panels and for receiving side collectors integratedwith a clip in one area and not integrated with a clip in another area.

FIG. 17 is a front view of a clip for use in assembling a structure.

FIG. 18 is a front view of FIG. 16 and FIG. 17 assembled.

FIG. 19 is a side view of an un-integrated side collector.

FIG. 20 is a front view of a connector for use in assembling astructure.

FIG. 21 is a front view of a clip for use in assembling a structure.

FIG. 22 is a front view of FIG. 19 to FIG. 21 assembled includingpanels.

FIG. 23 is a side view of a panel and a side collector separate from thepanel.

FIG. 24 is a front view of a connector for use in assembling astructure.

FIG. 25 is a front view of a clip for use in assembling a structure.

FIG. 26 is a front view of FIG. 23 to FIG. 25 assembled.

FIG. 27 is a side view of an embodiment wherein the connector is themale component and the side collector is the female component of anexemplary connector assembly.

FIG. 28 is a side view of an exemplary embodiment of a side collectorconfigured to mate with another side collector, e.g., tongue and groove,without the use of a connector.

FIG. 29 is a front view of a connector assembly comprising a connector,a clip, and a panel with an integrated side collector.

FIG. 30 is a graphical illustration of the deflection versus pressure ofa connector assembly having the design of FIG. 38 with various mountingconfigurations compared to a connector assembly having the design ofFIG. 12.

FIG. 31 is a graphical illustration of the deflection versus pressurefor a connector assembly having the design of FIG. 29 compared to aconnector assembly having the design of FIG. 38.

FIG. 32 is a graphical illustration of the deflection versus wind loadfor various spacing measurements for a connector assembly having thedesign of FIG. 12 with a 3 foot (0.9 meter) wide panel.

FIG. 33 is a graphical illustration of the deflection versus wind loadfor various spacing measurements for a connector assembly having thedesign of FIG. 38 with a 2 foot (0.6 meter) wide panel.

FIG. 34 is a graphical illustration of the deflection versus wind loadfor various spacing measurements for a connector assembly having thedesign of FIG. 12 with a 4 foot (1.2 meters) wide panel.

FIG. 35 is a graphical illustration of the deflection versus wind loadfor various spacing measurements for a connector assembly having thedesign of FIG. 12 with a 2 foot (0.6 meter) wide panel.

FIG. 36 is an assembled view of a photovoltaic module.

FIG. 37 is a front view of a clip having a lip to hold an assemblytogether when exposed to a load.

FIG. 38 is a front view of a connector assembly comprising a connector,a clip with a flat cross member, and an integrated side collector.

FIG. 39 is a front view of FIGS. 16 and 17 assembled and connected to aphotovoltaic panel.

FIG. 40 is a front view of FIGS. 16 and 17 assembled and connected to aphotovoltaic panel.

FIG. 41 is a side view of a standing seam side collector.

FIG. 42 is a front view of a connector for use with the collector ofFIG. 41.

DETAILED DESCRIPTION

Disclosed herein are various embodiments of connector assemblies, e.g.,connector(s) and collector(s), and clip(s). The connectors can attach toa support via the clip, where the clip can comprise an extensionprotruding from an edge of a cross-member. The extension can, when usedto attach multiple panels together, assist in keeping the panelsattached to one another when a load is applied. In other words, theextension can assist in keeping the panel assembly intact by effectiveresistance to positive and negative wind load force, thereby preventingseparation of the panels. The clips disclosed herein comprising anextension can hold the connector assembly together at higher wind loadsthan clips not comprising an extension. The connectors can also besingle or double sided; e.g., can be capable of engaging one or two setsof collectors, and optionally of engaging the ends of one or twoadditional panels with no collectors. The collectors can be integralwith the panel (formed as part of the panel, e.g., as a single, unitarycomponent), or separate from the panel as an independent component. Ifthe collector is a separate component, many different width panels(e.g., measured in the X direction) can be used with the same collectorand connector. Additionally, many different thicknesses (measured in theY direction) and/or different width panels can be used with the sameconnector by using different, separate collectors. Various designs canbe included to attach other components, including, but not limited to,for example, photovoltaic panels having frames designed to acceptconnectors (e.g., standing seam connectors) for ease of assembly.Additionally, the clips can be designed to enable the panels to be levelwhen assembled (in the Y direction). The clips can also be designed toengage with the panels so as to not allow separation between the paneland the clip in the X direction when subjected to a load. Optionally, asingle clip design can be used with several collector or integratedcollector designs.

The connector assemblies generally comprise a connector, a sidecollector, and a clip for attaching panels together. The connectors andcollectors are designed as mating pairs with one acting as the male andthe other as the female connector. In many of the embodimentsillustrated in the Figures, the connector is illustrated as the femalecomponent, while the collector is illustrated as the male component. Itis noted that this is merely for illustration and ease of discussion.The opposite configuration is also covered herein and contemplatedhereby, wherein the connector is the male component and the collector isthe female component (e.g., see FIG. 27). Therefore, the discussion ofthe cavity for the connector and the connector engagement region for thecollector can readily be reversed and is hereby understood.

The connector can be designed with a cavity that has a size and shape tomate with a pair of side collectors (from adjacent panels) in order tohold the panels together. The specific size and shape of the cavity isdependent upon the size and shape of the side collectors. Desirably, theconnector securely attaches to the panels, over the side collectors. Inother words, the size of the cavity can be about equal to the size ofthe side collectors such that when the connector is assembled onto theside collector, physical contact between the outer surface of the sidecollector and the inner surface of the cavity is attained (e.g., overgreater than or equal to 80% of the outer surface of the collector). Itis noted that when a clip is utilized having an engagement (e.g.,cross-member 24 in FIG. 1, receiver 52 in FIG. 17) that will be locatedbetween the connector and the collector, the size of the collector innersurface is sufficient to enable the engagement to be located between theconnector and collector. For ease of installation and minimization ofthe use of fasteners, the connectors can be designed to snap-fit ontothe collectors (e.g., see FIG. 4), to slide onto the collectors from anend of the panel (e.g., see FIG. 26), and/or to otherwise attach. It iscontemplated, however, that a sliding mechanism can also be used toattach the connectors to the collectors.

It is noted that the connector is complementary to the combination ofcollectors to which it connects. However, both collectors do not need tobe identical. Different collectors can be used on each panel so long asthe connector is designed to receive that combination of collectors.

Further, panels using the side collector(s) (and/or connectors)disclosed herein can have all of their edges—not just two opposingedges—bearing attachment structures. (See FIG. 36) For example, panelsfor a wall might bear edge connectors with standing seams where thehorizontal panel edges are to be joined and edge connectors with tongueand groove attachments where the vertical panel edges are to be joined.

For example, referring to FIGS. 1-4, the connector 100 has a cavity(interior portion 102) with a size and shape complementary to two sidecollectors 210 arranged adjacent to one another such that the collectorassembly (two adjacent side collectors) can be inserted into the cavity102. For example, such that the peaks 216 and slopes 218 of the adjacentside collectors form a valley that receives the connector protrusion120. Similarly, complementary flange 104 and ledge 220 of the connector100 and side collector 210, respectively, can be in physical contactwhen the connector is attached to the panels.

Some embodiments of the connectors 100 are “double” connectors, i.e.,they have cavities 102 on two opposite sides for receiving pairs of sidecollectors (e.g., see FIG. 16). In these embodiments, a cavity 102 islocated on each side of the header 134. Each of these cavities 102comprises the flanges 104 to engage the ledges 220 of the sidecollectors 210 (e.g., see FIG. 2). As with the other connectors 100, forexample as illustrated in FIG. 3, each cavity 102 of the doubleconnectors are configured to mate with a specific pair of sidecollectors 210 and therefore has a complementary inner geometry thatmatches the outer geometry of the side collectors (or, as is mentionedabove wherein the connector is the male element, the connector will havea complementary outer geometry to match the inner geometry of thecollector, wherein the collector will extend from the end of the panel).For example, as illustrated in FIG. 16, wing(s) 36 can be present thatmate with receiver(s) 52 extending from stem 22 on the clip 10. As isclear from the exemplary embodiments illustrated in the figures, each ofthe connectors in the double connector does not have to be identical. Acombination of different connectors can be used. As can be seen fromFIG. 16, the connector can have different shaped cavities 102 that areconfigured to receive the same shaped pairs of side collectors. It isalso contemplated that different shaped pairs of collectors can bereceived in each cavity that is shaped accordingly. Here, the differencein shape is to enable the additional receipt into one of the cavities,the clip engagement (e.g., cross-member(s) 24 and/or receiver(s) 52).

In addition to different cavity geometries, the connectors can comprisedifferent outer geometries, thereby enabling them to receive additionalpanel(s), e.g., panel(s) that do not have a side collector. Optionally,slot(s) (e.g., slots 150,152) can be formed between the cavities 102(see e.g., FIG. 16). The size and geometry of these slot(s) is dependentupon the thickness of the panel(s) intended to be inserted into theslot(s). Note, it can be desirable to only have slot(s) on the side(s)of the double connector intended to receive additional panels. Thepresence of a panel in the slot stabilizes the sides 154,156 of thedouble connector, preventing flexing of the side(s) after installationof the panel. In other words, while the side collectors 210 are insertedinto the cavities 102, the sides 154,156 (accordingly), of the doubleconnector, are forced outward, causing the edges 158,160 (accordingly)defining the slot(s) to move into the slot. Once the flange 104 passesthe end of the slide region 214 to the ledge 220, the sides 154,156 moveback out of the slot(s) 150,152. Hence, if a snap-fit arrangement isemployed, the side collectors are inserted into the double connectorprior to the insertion of the additional panels. Furthermore, if afastener is employed, the set of side collectors located between theconnector and the support are inserted first to enable the attachment ofthe fastener 302 to arm 30. Then the second set of side collectors areinserted into the open cavity 102 prior to the insertion of theadditional panel(s). The additional panels can have a thickness thatenables a compression fit in the slot, e.g., without damaging the end ofthe panel. Such a fit will prevent inadvertent removal of the panel fromthe slot and will stabilize the sides 154,156 against movement upon theapplication of force to the panels.

As is illustrated in FIG. 18 and mentioned above, the end of the panels(without collectors) can be inserted into the slot(s). This creates anarrangement, in the Y direction (see coordinate system labeled in FIG.18), of panels with collectors (e.g., first set of panels), gap (e.g.,fluid gap such as air), panels without collector, gap (e.g., fluid gapsuch as air), panels with collectors (second set of panels). Since thesizes of the slots are different, different thickness panels are locatedon each side of the double collector. In embodiments that employ thedouble connector, a clip can optionally be employed to provideattachment of the first set of panels to a support 300. In addition, theclip may further comprise member(s) 38 configured to receive fastener(s)302. Hence, one or both of the connectors of the double connector can beconfigured to receive fastener(s) to enable further securement of theconnectors (and hence the panels) to the support 300. In other words, inaddition to the snap connection via the side collectors of the first setof panels, the retention of the connectors can be further enhanced viadirect attachment of the header of the double connector to the member(s)38 of the clip 10 via the use of connecting member 276.

Some further exemplary embodiments of additional connectors are setforth in FIGS. 10, 20, and 24. These embodiments further illustrate thatthe specific size and geometry of the connector is only limited by thesize and geometry of the side collectors and clip to which it will beconnected. Also, as is clear with respect to the panels and the sidecollectors, the connectors can optionally comprise various combinationsof ribs 162 (e.g., horizontal, vertical, diagonal, and any combinationthereof) as is desired, e.g., for additional structural integrity (e.g.,see FIGS. 3 and 16). Any rib arrangement is based upon desiredstructural integrity for the particular connector, based upon where theconnector will be employed and the loads it will experience.

The side collector(s) are located at the end of the panel, whereinadjacent side collectors (from adjacent panels) form the seam betweenthe panels to be connected. As noted above, the side collectors can havevarious designs that are complementary to the design of the connectorand clip so as to enable the collectors (male portion; connectorengagement region 222 with a head 234) to mate with the connector(female portion; cavity 102) (or collectors (female portion) to matewith the connector (male portion)), e.g., see FIG. 23 and FIG. 24.

The specific geometry of the collectors are dependent upon the geometryof the connector to which they will be mated. Some exemplary geometriesare illustrated in FIGS. 2, 9, 19, and 23. As can be seen in thesefigures, the collectors can optionally comprise rib(s) 226 (e.g.,vertical, horizontal, and/or diagonal to enhance the structuralintegrity of the collector. It is also noted that the density of theribs (number of ribs per unit area), can be greater than the density ofthe ribs in the panel (if the collector is separate) or in the remainderof the panel (if the collector is integral). Diagonal ribs, for example,can be used along with vertical ribs and horizontal ribs in the areaadjacent the panel engagement region 224. In this embodiment verticalribs and horizontal ribs are employed throughout the side collector,with diagonal ribs only located in the area adjacent the panelengagement region 224 (e.g., no diagonal ribs are used in the connectorengagement region).

As noted, the side collectors can be an integral part of the panel(e.g., see FIG. 2), or a separate component (e.g., see FIG. 19), e.g., aside collector formed separate from the panel and later attached to thepanels (e.g., after manufacturing of the panel is complete).Non-integral side collectors, such as tongue and groove, base and cap,and standing seam side collectors are advantageous in that panel sizes(e.g., length, width, height, and/or thickness) are not limited by sizesthat are already produced because of cost issues associated withcreating, testing, and validating a new die system to produce thedesired size. With non-integral side collectors, any size andcombination of panels and/or sheets can be used, since the sidecollectors are produced separate from the sheet and attached at a latertime (e.g., at or close to the job site). Additionally, different shapeside collectors can be used to attach different panels of a system(e.g., roof) together. This enables the side collectors and connectorsto be customized for the particular location and desired properties(e.g., to enhance structural integrity, sound dampening, and/or lighttransmission, etc.) Non-integral side collectors are additionallyadvantageous in that they essentially convert a standard panel (e.g., aplanar panel with no side collector) into a modular panel. These sidecollectors can have a structure configured to wrap around an edge of apanel, (e.g., a U-shape) and be sized to receive the thickness(s) of thepanel(s) to be fit therein. These side collector(s) can be welded (e.g.,ultrasonically and/or thermally), chemically attached (e.g., chemicallybonded or glued), and/or mechanically attached (e.g., screwed, bolted,riveted, etc.) and/or otherwise affixed to the panel(s).

As discussed above, the side collectors have a complementary design tothe connectors so as to enable mating thereof. In many embodiments,these components can be snap-fit together. Hence, the side collector 210comprises an area that enables the connector to readily move over thesurface of the side collector, such that when a force is exerted on theconnector toward the side collector, the sides 156 of the connector flexoutward, away from the cavity 102 (see FIGS. 2-4). This enables theconnector engagement region 222 to enter the cavity 102 until the flange104 contacts the ledge 220, thereby allowing the sides 156 to move backtoward the cavity 102.

Alternatively, in the various embodiments, if flexing of the sides 156of the connector is not possible and/or not desirable, the connector canbe disposed onto the collector by placing the side collectors of twopanes adjacent to one another. The connector and collectors can be movedtogether (e.g., in the Z direction), sliding the connector andcollectors together (e.g., sliding the connector engagement region 222into the cavity 102).

When the collector is a separate element from the panel, it comprises apanel engagement region 224 (see FIGS. 9, 10, 19, and 23). The height ofthe panel engagement region 224 is sufficient to enable an end of apanel to be inserted therein (e.g., is sized to receive thethickness(es) of the panel(s) to be fit therein (see FIGS. 22 and 26)).Depending upon the design of the collector, the receiving area 232 canbe defined by the connector engagement portion 222, collector arm(s)230, and/or rib(s) 226. For example, in FIG. 19, the receiving area 232is defined by the connector engagement portion 222 and arm 230. In FIG.23, the panel engagement region 224 has an arm 230, but the receivingarea 232 is defined by the connector engagement portion 222 andhorizontal rib 226. In FIGS. 9 and 10, the receiving area 232 is definedby arms 230. In some designs, the arms 230 extend outward, e.g., fromthe connector engaging area (see FIGS. 8-10, 27, and 28), e.g., suchthat the panel engagement region comprises a body portion 262 which islocated adjacent to the connector engaging region (see FIGS. 8 and 9)and arm(s) 230 extending from the body portion 262, forming receivingarea 232 for attachment onto an edge of a panel. In other embodiments,the arms 230 are located in alignment with the connector engaging region(see FIGS. 19, and 23), e.g., such that the panel engagement region islocated adjacent the connector engaging region (e.g., the panelengagement region is formed by the arms 230 (which may be multiwalled),and no body portion).

Within the panel engagement region 224 can be energy director(s) 228extending into the receiving area 232. These energy directors can beconfigured to engage an outer surface (e.g., surface 208 of FIG. 12) ofthe panel to which the collector will be attached. The energy directorscan aide in grasping and retaining the panel in the panel engagementregion 224 of receiving area 232 and/or can redirect energy received bythe collector and/or panel (e.g., during welding (e.g., ultrasonicwelding, laser welding, and/or thermal welding) together of thecollector and panel) into the ribs 198 of the panel (see e.g., FIG. 2).Therefore, desirably, some or all of the energy directors 228 arelocated in the receiving area 232 so as to align with vertical ribs(e.g., ribs extending in the Y direction) in the panel when the panel isinserted into the panel engagement region 224. The energy director(s)can be located on one or both horizontal surfaces (surfaces extending inthe X direction) in the receiving area 232. To inhibit the arms fromdetaching from the panel, and/or to avoid moisture, air, and/or insectinfiltration, an energy director can be located at the end of each arm246 (e.g., FIG. 28). Furthermore, it was discovered that the strongestbond between an attachment member and a multiwall panel came about whenan energy director was positioned directly over a vertical rib in amultiwall structure. Energy director(s) can be used on the verticalsurface as in FIG. 19 when the panel has a closed end (e.g., is not opento the individual ribs), and has horizontal ribs or when the panel is asolid panel.

The number of energy director(s) employed can be different on eachhorizontal surface (and optionally the vertical surface), and can varydepending upon the length of the horizontal surfaces, the amount ofvertical rib(s), if any, (and, if on the vertical surface, the amount ofhorizontal ribs) in the panel, and/or the amount of force that will beexerted onto the collector and/or panel when they are assembledtogether. For example, in the case of the multiwall panel, greater thanor equal to 2 energy directors are generally employed on each horizontalsurface, specifically, greater than or equal to 4, more specifically,greater than or equal to 5, and yet more specifically, greater than orequal to 8. Although any geometry can be employed for the energydirector 228, a generally triangular geometry is employed, e.g., anisosceles triangle extending into receiving area (such as from thearm(s) 230). The height of the energy director (e.g., the distance theenergy director extends from arm 230 into receiving area 232) can vary.Generally the height is less than or equal to 5 mm (millimeters),specifically, 0.25 mm to 2 mm, more specifically, 0.5 to 1 mm.

The energy directors can be formed as an integral part of the collector(i.e., an extension from arm 230, not an attachment to arm 230).Furthermore, to enhance compatibility between the collector and thepanel, the energy director(s) can be formed from the same type ofmaterial as the panel, or can be a composition comprising the same typeof material as the panel. For example if the panel is a polycarbonatepanel, the energy director(s) can be polycarbonate, or a compositioncomprising polycarbonate, such as a polycarbonate and ABS.

Not to be limited by theory, it is believed that, e.g., duringultrasonic welding the energy directors pinpoint the energy of thevibrating ultrasonic horn to a small area between the side collector andpanel (apex of the triangle) causing the energy director to melt andsubsequently fuse the side collector and panel together. Without theenergy directors, the ultrasonic horn would vibrate, heat, and compressa large unmelted side collector into the panel, crushing a multiwallpanel or creating a very weak bond with a solid panel. In addition oralternative to the welding, the side collectors 210 can also be attachedto the panel by laser welding, by chemical, and/or mechanical methods(e.g., gluing, chemical bonding, fastener(s), and combinationscomprising at least one of the foregoing).

Bonding a separate side collector to a panel can comprise inserting theedge of the panel into the receiving area of the side collector untilthe edge contacts the vertical wall and/or the panel cannot be insertedany further and creating relative motion between an ultrasonic weldinghorn and the arms of the side collector so as to melt the energydirector(s) and form a bond between the arm and the panel surface.

To address thermal expansion of the panels, the side collectors can havea joint side with an angled wall (e.g., angled from the connectorengagement region toward the receiving area) such that, when assembled,the joint walls 254 form a joint (e.g., space 252) having a decreasingwidth from the base 258 toward the point 264 (see FIG. 10). In otherwords, the joint wall can be non-perpendicular, as determined withrespect to the arm 230. The joint walls form a space having a convergingdiameter from the base 258 toward the connector engagement region 222,and optionally all the way to the point 264 adjacent the end of thejoint wall 254 opposite the base 258. The size of the space formed bythe adjacent walls should be sufficient to enable the thermal expansionof the panels to which the side collectors are attached. Essentially, asthe panels thermally expand, they would exert a force on the sidecollectors, causing the side collectors to move toward each other. Asthe side collectors move toward one another, the width (as measured inthe X direction), of the space decreases. The space can have a width (asmeasured in the X direction, and in the relaxed state (i.e., when noforce is applied due to thermally expanding panels)), at the base 258,of greater than or equal to 1 mm, specifically, 2 mm to 10 mm, and morespecifically, 2.5 mm to 5 mm.

Alternatively, or in addition to the joint 252, a spacer 250 can belocated between adjacent joint walls 254. The spacer can comprise aflexible material that can be compressed by expanding panels, e.g., afoam or elastomeric material (see FIG. 8). The spacer can have asufficient size and compressibility to allow for the thermal expansionof the panels. For example, the spacer can have a thickness (measured inthe X direction and in the non-compressed state) of greater than orequal to 1 mm, specifically, 2 mm to 10 mm, and more specifically, 4 mmto 8 mm.

When the side collector is to be used with an alignment clip that willnot engage the outer surface of the side collector and/or the connector,the side collector has an opening 212 to receive the cross-member 24 ofthe clip 10 (e.g., see FIGS. 2 and 10). This opening is located in thejoint wall 254 adjacent the receiving area 232.

As is mentioned, a clip can be employed with the connector andcollectors. Different types of clips are possible. For example, the clipcan be an alignment clip (e.g., see FIG. 1), and/or a combinationalignment clip and engagement clip (e.g., FIGS. 17, 21, and 25). Hence,the clip can comprise an alignment region that is designed to align theadjacent panels such that when the panels are attached together, theyare level. For example, in FIG. 1, the clip 10 is illustrated ascomprising a cross-member 24 at one end of stem 22 and a base 18 at theother end. The base 18 can have a foot 28, side(s) 12,14, leg(s) 16,area 20, and/or support(s) 26, e.g., the base can form a “u” shape(e.g., with a side 14, leg 16, and arm 30 (see FIGS. 2 and 21), or withlegs 16 and foot 28 (see FIG. 25)). For example, as is illustrated inFIGS. 1, 4, and 21, the base can comprise sides 12,14 (extending in theY directing away from the engagement) defining area 20, with arm 30extending from the side 14 to leg 16 (which extends in the Y directiontoward the engagement). The foot 28 can extend away from stem 22 in oneor both directions, e.g., forming a L-shaped foot or a T-shape (seeFIGS. 1, 17, 21, and 25), with the stem, respectively. The T-shaped stemallows even alignment of the assembled panels since both of the adjacentpanels are held the same distance from the support. However, theL-shaped foot only extends along one panel and hence does not supportthe panels evenly when assembled (e.g., the panels will be offset by thethickness of the foot 28).

Building codes often require panel and connector assemblies be able towithstand wind loads of 80 mph to 280 mph (130 kph to 450 kph) withoutfailing. Such wind loads can create a “negative wind load” that can pulla roof or wall from its supports with forces of 16 pounds per squarefoot (lb/ft²) to 200 lb/ft² (about 766 Pascals (Pa) to about 9576 Pa). Apotential failure mode can be observed in connector assemblies exposedto such wind loads in that the panels can separate from one another atthe attachment point due to deflection and subsequent release of theclip from the attachment point. The clip 10 in FIG. 1 can be modified toincorporate features that can help prevent the separation of adjoiningpanels and thus, prevent subsequent release from the attachment pointand failure of the connector and panel assembly.

For example, referring now to FIG. 5, which is a cross-sectional view ofthe cross-member 24 and stem 22 of clip 10, the various design featuresto aid in preventing disassembly during wind loading are illustrated.FIGS. 6 and 7 also illustrate various designs of clip 10 incorporatingthe design features described herein. For example, as illustrated inFIG. 5, the cross-member 24 can comprise extensions 44, 46 that areconfigured to engage with the opening 212 in side collector 210 toassist prevention of separation of the panels, e.g., to preventseparation of panels 200,202 as illustrated in FIG. 4 when facing a windload (e.g., a negative wind load). Cross-member 24 can, itself, bedesigned so that the extension is a lip 44 on either or both sides ofthe cross-member 24 (e.g., first side 48 and/or second side 50). Asillustrated in FIG. 5, the lip 44 can protrude upward and/or downwardfrom either side 48 and 50 of cross-member 24. One embodiment of a clip10 comprising a lip 44 protruding downward from cross-member 24 isillustrated in FIG. 7; another possible design is illustrated in FIG.11. In embodiments where lip 44 is present, the opening 212 in sidecollector 210 can, optionally, be modified as shown in FIG. 12, i.e.,opening 212 can be modified to accommodate (i.e., compliment or match)the lip 44. In FIG. 11, another embodiment of clip 10 is illustratedhaving a lip extending from the second side of the cross-member 24 toengage with an opening 212 in a side collector 210.

Cross-member 24 can also, alternatively, or in addition to lip 44 haveprotrusion 46 protruding therefrom on either or both sides 48,50 upwardor downward as illustrated in FIG. 5. FIG. 6 illustrates a clip 10 withprotrusion 46 extending downward from cross-member 24. Protrusion 46 canbe configured to penetrate into the side collector 210 in the area ofthe opening 212, creating a gripping effect and being able to preventdisassembly of the connector assembly 70. FIG. 7 illustrates anembodiment where a clip can also, optionally, comprise protrusion 46extending from the foot 28 of the clip 10 with a lip extending from thesecond side 50 of the cross-member 24 so that lip 44 and protrusion 46face one another. For example, as illustrated in FIG. 7, the protrusion46 can be pointed inward for ease of assembly and to make disassemblymore difficult. It is contemplated, however, that the protrusion 46 canbe oriented in any direction that will provide the desired panelretention when a force is applied. It is to be understood that anycombination of lip 44 and protrusion 46 can be included in any of theembodiments disclosed herein.

FIG. 12 illustrates a connector assembly 70 with a cross-member 24having lip 44 that is not under a load, while FIG. 13 illustrates thesame, but under a negative wind load. In FIG. 12, arm 30 can be used toattach the clip 10, and hence, panels 200,202 to a support structure 40using a fastener 302 having a fastener head 304. Exemplary fastenersinclude a bolt, screw, nail, rivet, nut, peg, glue, two-sided tape, aswell as combinations comprising at least one of the foregoing. Exemplarysupports include a beam (e.g., purlin, I-beam, rectangular beam, etc.),piling, wall, a rafter, post, header, pillar, roof truss, as well ascombinations comprising at least one of the foregoing. As illustrated inFIG. 12, the clip can comprise multiple legs 16 and supports 26 that canprovide design flexibility while providing solutions for variousapplicable building codes and can also support panels 200,202 and canmaintain level spacing between panels 200,202.

As can be seen in FIG. 13, when under a negative wind load, there can beuplift in the Y direction (see coordinate system illustrated in FIG. 18)of the connector assembly 70, but the lip 44 is able to engage withopening 212 in the side collector 210 to prevent side collectors 210 andthus, panels 200 and 202 from separating from one another. (e.g., resistX direction separation). For example, when the panel 200,202 experiencesa negative wind load, the panel 200,202 can be pulled so that only theclip 10 holds the panel to the structure. The lip 44 effectively createsa mechanical stop preventing the panels from detaching. FIG. 13additionally illustrates that the panel engagement region 224 can,optionally, comprise energy directors 228 as described in more detailwith respect to FIG. 28.

If the opening 212 of the side collector 210 is not modified to matchwith the lip 44 of the clip 10, the lip 44 can still function to holdthe side collectors 210 and panels 200,202 together due to increasedconcentrated pressure of the lip 44. The material of the side collector210 will yield to the lip 44 and the lip 44 can penetrate into the sidecollector 210 in the area of the opening 212, creating a gripping effect(e.g., mechanical stop) to assist the connector assembly 70 fromdisassembling when under load.

Insertion of the clip 10 with the lip 44 can be accomplished by ensuringthe thickness (h) of the clip 10 is less than opening 212 in the sidecollector 210 (see e.g., FIGS. 11 and 12). It is contemplated that theclip 10 can be slid in from either or both ends of the panels which areto be interconnected, which would allow for a constricted or even forcefit between the thickness (h) of the clip and the opening 212 in theside collector 210. Additionally, it is contemplated that the clip 10could be forced into the opening 212 from the side of the panel if thethickness of the clip 10 was larger than the opening 212.

As illustrated in FIGS. 12 and 13, the tolerance between the thicknessand height of the opening 212 in the collector 72 and the thickness (h)and height (t) of the lip 44 (see e.g., FIG. 11) can create a floatingeffect in the connector assembly 70 that can provide allowances forthermal expansion as well as the ability to slide the panels along theclip after assembly. Alternatively, or in addition to, a zero tolerancesituation can occur in which the ability to slide the panel isrestricted and the clips can be slid onto the panel from an end of thepanel and moved into place before securing from a side or bottom of theclip. FIG. 37 illustrates a clip 60 that can be used in this embodimentwhere the clip comprises a cross-member 24 having a lip 44 with a foot28 connected to a side 14 with a landing 62 extending therefrom.

Turning again now to FIG. 12, when the clip 10 is assembled onto panels200, 202, arm 30 on the clip 10 can be used to attach the clip 10 andthus, panels 200,202 to a support structure 40 using fastener 302.Exemplary fasteners include a bolt, screw, nail, rivet, nut, peg, glue,two-sided tape, as well as combinations comprising at least one of theforegoing. Exemplary supports include a beam (e.g., purlin, I-beam,rectangular beam, etc.), piling, wall, a rafter, post, header, pillar,roof truss, as well as combinations comprising at least one of theforegoing.

FIG. 14 is an embodiment of a panel (e.g., LEXAN* THERMOCLICK) panelwhere the panel is modified to accommodate a clip 10 having the designillustrated in FIG. 11. Similarly, FIG. 15 is an embodiment where a clip10 having the design illustrated in FIG. 11 is connected to panelshaving a lap joint connection 68.

When the clip 10 is assembled onto adjacent panels 200,202 (see FIG. 4),side 12 is adjacent the first panel 200, while side 14 is adjacent thesecond panel 202. Arm 30 (FIG. 1) can be used to attach the clip 10, andhence the panels 200,202, to a support 300 using fastener(s) 302.Similarly, when an arm 30 is not present, fastener(s) 302 can beattached to the support 300 through the foot 28 (see FIG. 17). Exemplaryfasteners include a bolt, screw, nail, rivet, nut, peg, glue, two-sidedtape, as well as combinations comprising at least one of the foregoing.Exemplary supports include a beam (e.g., purlin, I-beam, rectangularbeam, etc.), piling, wall, a rafter, post, header, pillar, roof truss,as well as combinations comprising at least one of the foregoing.

In order to prevent the panels 200,202 from being unlevel due to thepresence of the fastener 302, the side(s) 12,14, and/or leg(s) 16 have alength “l”, and/or the solid area 20 has a thickness, that is greaterthan or equal to the height “h” that the fastener head 304 extends fromthe linear portion 22 (e.g., stem 22) toward the panels. If there is adifference in the thickness of the panels (in the Y direction), theside(s) 12,14, and/or leg(s) 16 have a length “l”, and/or the solid area20 has a thickness (as is appropriate), to compensate for the differencein the panels' thicknesses, such that, when the panels, connector, andclip are assembled together, the outer surface 208 of the panels arelevel with one another; they are aligned. In other words, the side(s)12,14, and/or leg(s) 16 have different length “l”, and/or the solid area20 has a different thickness, wherein the difference in thelength/thickness is equal to the difference in the panels' thicknesses.

Further structural integrity can be attained in the clip via the use ofan optional extension from the leg(s) 16 and/or sides 12,14, e.g.,support 26. Lateral extension(s) (e.g., support) 26 (e.g., see FIGS. 1,11, 17, 21, and 25) can be employed with the various embodiments of theclip, wherein the lateral extension(s) can extend toward and/or awayfrom the adjacent panel to which the clip is connected. For example, thelateral extension(s) can extend toward and/or away from the stem 22 (inthe X direction). These extension(s) can provide support to the panel aswell as can inhibit air, water, and/or insect infiltration.

At the end of the stem 22 opposite the foot 28 is an engagement that canbe located in an opening in the side collector and/or can contact asurface of the side collector. Exemplary engagements include across-member 24 (see FIGS. 1 and 21), receiver(s) 52 (see FIG. 17),and/or support structure 40 (see FIG. 12). In various embodiments, theengagement can have a generally T-shape (e.g., the cross-member 24 islocated perpendicular to the stem 22), and/or can be arcuate (e.g.,extending from the stem 22 in a manner complementary to the shape of theside collector slide region 214 (e.g., FIG. 17 receiver 52 incombination with FIG. 16). Stated another way, a receiver(s) 52 candiverge from the stem 22 at an end opposite the base 18. Hence, theengagement can be configured to be located in an opening in the sidecollector (see FIGS. 2 and 4, opening 212 in side collector 210), orcan, when assembled, be located between the side collector (e.g., theslide region 214) and the connector (e.g., the inner surface 122 (seee.g., FIG. 3) (see also FIG. 26, receiver(s) 52 contacting surface(slide region) 214). When the engagement is configured to be located inthe opening 212, the stem has a length that is less than the height ofthe receiving area (e.g., both measured in the Y direction). In otherwords, the stem has a length that is less than the thickness of thepanel that will be received in the receiving area 232 (see e.g., FIG.10).

As illustrated in FIGS. 21 and 22, cross-member 24 can comprise anextension (e.g., protrusion 46) on the second side 50 of thecross-member 24 which will engage with the panels 200,202 of FIG. 22 toassist in preventing panel separation when a load is applied to theassembly. FIGS. 25 and 26 illustrate yet another embodiment whereextensions can be present on cross-member 24 (e.g., on the first side 48and/or on the second side 50). For example, as illustrated in FIGS. 25and 26, protrusion 46 can be located on cross-member 24. It iscontemplated, however, that lip 44 could also be present on cross-member24, as well as any combination of lip 44 and protrusion 46.

The cross-member 24 can extend out from the stem 22 in the “X” plane(e.g., see FIGS. 1, 11, 21, and 25), in one or both directions (e.g.,positive and negative) and the distance in each direction can be thesame or different. Similarly, one or more wings can extend from the stem22 along the “X” plane, in one or both directions, with the length ofthe wings being the same or different (see FIG. 17). Larger wing widthscan provide higher wind loads. The desired width of the wings (e.g.,from the end of one wing to the end of the other wing), is thereforedependent upon the intended application and desired structuralintegrity. Wing spans of up to and exceeding 50 mm can be employed,specifically spans of 5 mm to 40 mm, and more specifically spans of 10mm to 30 mm.

With respect to the angle at which the cross member 24 and lip 44 extendfrom the stem 22, it is also determined based upon desired structuralintegrity and the desired shape of the side collector to which the clipwill connect. The cross-members can extend from the stem at an angle θof 85° to 95°, with an angle of 90° desirable to enable higher loadings.An angle θ of more than 90° reduces load potential while an angle θ ofless than 90 inhibits assembly of the panels and the clip, and canhinder assembly. The wings are generally curved and extend from the stem22 at an angle θ of 100° to 155°, specifically, 35° to 75°, and morespecifically, 40° to 50°. For example, clips having an angle θ of 90°have a loading capacity of 100 lb/ft² (4,788 Pa), while at an angle of135°, the clip (comprising the same material and thickness), has aloading capacity of less than 80 lb/ft² (3,830 Pa).

The length of the clip (i.e., in the Z direction, see coordinate systemillustrated in FIG. 18) is also dependent upon desired structuralintegrity (e.g., wind load resistance). When maximum wind loadresistance is desired, the clip length is equal to the length of thepanel. When less resistance is needed, the clip can have a length thatis less than or equal to 50% of the length of the panel, specificallyless than or equal to 25% of the length of the panel, and morespecifically, less than or equal to 10% of the length of the panel. Forexample, the clip length can be less than or equal to 24 inches (61centimeters (cm)), specifically, less than or equal to 12 inches (30.5cm), more specifically, less than or equal to 6 inches (15.2 cm), yetmore specifically, less than or equal to 3 inches (7.6 cm), and evenless than or equal to 2 inches (5.1 cm).

In addition to the cross-member(s) 24 and/or receiver(s) 52, theengagement can further comprise member(s) 38. The member(s) 38 areconfigured to receive a portion of the connector and/or fastener(s)(e.g., to receive protrusion 120 into region 42 defined by member(s) 38;see FIGS. 20 and 21; and/or to receive fastener 302 (see FIG. 12)).Therefore, the member(s) 38 can optionally be threaded, and/or comprisean adhesive or bonding agent, e.g., to facilitate retention between theclip and the connector. In addition to the member, support structure 40may extend outward from the member and to the wing to provide additionalstructural integrity to the member (see FIG. 17). The geometry of thesupport structure is preferably complementary (e.g., the negative) ofthe geometry of the portion of the connector and/or collector to whichit will be adjacent when assembled.

The stem 22 extends from a base 18 (e.g., from the foot 28) to theengagement. Therefore, if the engagement is configured to be located inthe opening 212, the stem 22 will have a length that is less than thethickness of the panel, while if the engagement is configured tophysically contact the surface of the side collector, the stem 22 willhave a length that is greater than or equal to the thickness of thepanel (measured in the Y plane).

Referring to FIG. 27, this figure is intended to show that the aboveconfigurations can be reversed such that the connector is the maleelement and the side collectors form the female element to enable matingof these components. In this exemplary embodiment, when the sidecollectors are assembled together, the joint walls 274 form the cavity272. As with the other embodiments, any complementary mating engagementcan be employed, such as snap-fit, tongue-and-groove, etc. The connectorcan further be attached to one or both of the side collectors with aclip 10 and fastener 302. As can be seen from the figure, thisarrangement enables a small profile since there is a minimum amount ofconnector and no side collector, extending away from the panels. Thedistance that the support 166 of the side collector extends away fromthe side collector 210 is dependent upon the size of the panels and theclips. For example, the support 166 can have a thickness (measured inthe Y direction), that is less than or equal to 30% of the thickness ofthe panel (measured in the Y direction), specifically, less than orequal to 20%, and even less than or equal to 10%. In some embodiments,the support has a thickness of less than or equal to 40 mm,specifically, less than or equal to 30 mm, and more specifically, lessthan or equal to 20 mm, and even less than or equal to 10 mm.

Referring to FIG. 28, exemplary embodiments illustrating connectorassemblies that use the side collectors to hold the panels togetherwithout the need for connectors. In these embodiments, mating pairs ofside collectors have complementary geometries (e.g., tongue-and-groove(FIG. 28)). In these embodiments, the side collectors do not have mirrorgeometries with each other (e.g., as is illustrated in many of the otherfigures. They have complementary, mating geometries that enable the twoside collectors to fixedly mate (e.g., to hold together so as separateonly when intentionally disassembled). In many embodiments of these sidecollectors, and even of the above connector/side collector groups, theelements permanently mate (e.g., once the elements are assembled theycannot be disassembled without breaking one or more of the components).

The connector, side collector, and clip can, independent of the otherelements, comprise any material that gives the desired properties (e.g.,light transmission, insulation, strength, durability, and/or impactresistance, etc.). For example, they can each independently comprise ametal (e.g., aluminum), a polymeric material (e.g., acrylic,polycarbonate, etc.), or combinations comprising at least one of theforegoing. For example, the clip can comprise aluminum (e.g., 6000series aluminum such as aluminum 6061; 7000 series aluminum such asaluminum 7108 or aluminum 7055; stainless; and other metals that willallow the clip to provide the desired wind load protection to theconnector assembly as well as combinations comprising at least one ofthe foregoing. Panels, side collectors, and/or connectors canoptionally, independently, be solid or hollow (e.g., multiwall, forexample comprising support structures, such as ribs). If the ribs arepresent, the density and configuration (straight, angled, parallel,perpendicular, etc.) of the ribs, is merely dependent upon the desiredstructural integrity and transmissivity of the particular element. Forthe side collectors and connectors, the ribs can have a thickness of upto 1 mm, specifically, 0.25 to 0.75 mm, and more specifically, 0.35 to0.6 mm. In some embodiments, the diagonal ribs have a greater thicknessthan the parallel and/or perpendicular ribs (wherein parallel andperpendicular are determined in relation to the X direction). Diagonalribs are ribs that are neither parallel nor perpendicular. In otherwords diagonal ribs not parallel or perpendicular to the panel outersurface when the element (collector or connector) is attached to thepanel. Diagonal ribs provide improved stiffness in all directionscompared to vertical and horizontal ribs. Ribs, particularly diagonalribs, can be used to tune the degree of stiffness (e.g., flexibility ofthe elements). Desirably, the connector engagement region of the sidecollector is stiff (rigid such that it does not flex or bend when beingassembled with the connector), while the connector has flexible sides156 (e.g., FIG. 16) to enable it to be assembled over the sidecollector.

If multiwall panels are used, any number of layers or sheets can beused, with any combination of support structures being contemplated foruse. Owing to the connector assemblies (e.g., to the separate sidecollectors), one can choose a panel having any desired thickness,structure (multiwall or solid), color, width/length, and shape, andadapt its edges to bear edge connectors having the desired attachmentstructure, and affix it to other panels having edge connectors withcomplementary attachment structure. Standard panel thicknesses are 4,4.5, 6, 8, 10, 16, 20, 25, 32, 35, 40, 45 and 50 mm, and further,different varieties of multiwall panels are available, generally having2 to 10 layers, specifically, 2 to 6 layers (e.g., with 1 to 5 cellsacross the panel thickness). Also, the cavities can have a variety ofinternal structures (rectangular passages, triangular passages, etc.).For example, the panels can be solid, hollow, or a combination thereof(e.g., can be multiwall panels wherein cavities of the panels are hollowand may optionally be filled, e.g., comprise a gas, a fluid, and/or asolid, depending on the desired properties of the structure (e.g.,soundproof, heat transmission, light transmission, weight, etc.).

Furthermore, conceivably, due to the flexibility attained with the sidecollectors, radically different panels (e.g., a 4 mm solid panel and a32 mm multiwall panel) can be fit together, so long as the panels wereeach fit with side collectors having complementary attachmentstructures. For example, the panel can be a functional panel such as aphotovoltaic panel designed to be a portion of the structure with thestructural integrity of solid, hollow, or filled panels. For example,the panels can optionally be arranged so that there is a space betweenadjacent stacked panels (e.g., see FIG. 18) or without space between theadjacent stacked panels and the panels can be solid, hollow (which, forexample, could be useful for cooling functional panels generating and/orabsorbing heat), and/or filled (with a fluid such as a liquid, gel,and/or gas), with a variety of rib configurations (e.g., see FIG. 18).Other functional panels can include, but are not limited to skylightinserts, infrared absorbing and/or reflecting structures, solar waterheaters, electrical roof fans, plastic fan blades driven by heatconvection, etc. For example, as illustrated in FIGS. 39 and 40, adouble sided connector and clip can be assembled with a photovoltaicpanel 500 in slot 150,152 (see FIG. 16). FIG. 36 illustrates an exampleof a photovoltaic panel 500. The double side connector and clip are thesame as previously discussed with respect to FIGS. 16 to 18. FIG. 40illustrates an embodiment where a flexible photovoltaic panel 502 can bebonded to a multiwall sheet or to a standing seam and inserted into slot150, while another panel 504 can, optionally, be inserted into slot 152,while FIG. 39 illustrates an embodiment where a photovoltaic panel 500can be directed inserted into slot 152 or where the photovoltaic panel500 can, optionally, be bonded to a solid or multiwall sheet andinserted into slot 152 and another panel 506 can, optionally, beinserted into slot 150.

Once the side collector is attached to the panel (or if it is integral)assembly of the panels with the connector assembly can compriseinserting a clip into the side collector (e.g., where it engages therectangular cut out). In other words, sliding the cross-member into theopening in the side collector. The clip can then be fastened to thesupport. A second panel, with side collector attached, can be slid upagainst the first panel so that the two touch or are in close proximityand so that the side collector of the second panel engages the clip.Finally, the connector is attached to the extended legs of the sidecollectors (i.e., to the connector engagement region) to secureeverything together.

The connector(s), collectors, and clips can be formed using varioustechniques, such as extrusion (e.g., a metal/plastic co-extrusion (i.e.,pultruded metal with encapsulated metal parts with plastic), a plasticcoextrusion with a cap layer (e.g., for ultraviolet protection, and soforth)). Metal pultrusion with encapsulated metal parts with plastic canbe used to attain enhanced rigidity to withstand very high forces suchas hurricane force winds. The metal could be incorporated in the area(s)of the plastic. For example, referring to FIGS. 41 and 42, the metal 260(e.g., coextruded metal) could be coextruded with the plastic to provideenhanced structural integrity to the arms 230, opening 212, and/or partor all of the joint side of the collector (e.g., from the bottom to theopening 212). In some embodiments, the metal is coextruded in the areaof one or both arms, and/or along the base 258, and/or along the jointwall 254. The metal can extend up the joint wall 254 along the entirebody portion, and/or from the base 258 up to and/or through the opening212 (if present). In some embodiments, the metal is coextruded along thebase and joint wall, but not along the arms.

An advantage of the methods disclosed herein is that bonding secondaryelements (e.g., collectors) to either multiwall or solid sheet productsrelying on adhesive systems are messy and have an extensive manualelement. Ultrasonic welding techniques without energy directors employedin the past resulted in poor bond strength and/or crushed multiwallpanels. Other mechanical fastening or heat welding techniques resultedin surface blemishes or other unsightly marks on the materials surface.The technique disclosed herein includes a bonding technique whichprovides for an intimate bond between similar materials making up thepanel and the attachment. The use of the energy directors can facilitatethe bond between the attachment elements (the side collector and thepanel, the connector and the side collector, etc. (e.g., standing seamleg, tongue or groove attachment, snap attachment, etc.)). It wasdiscovered that the inclusion of these energy directors enables the useof ultrasonic welding without crushing the multiwall panel or creating aweak bond between two flat polymer surfaces.

Also referring to FIGS. 41 and 42, optionally, the side collector(s)and/or connectors can have barrier elements to enable water, air, and/orbug infiltration resistance. These barrier elements can comprise a ridgeand a valley, wherein the mating ridge and valley are roundedcomponents. For example, they can form greater than or equal to 40% of acircle, specifically, greater than or equal to 50% (e.g., can form asemicircle). Exemplary barrier elements are illustrated in FIGS. 41 and42, wherein the barrier valley 242 on FIG. 41 is configured to mate withthe barrier ridge 244 on FIG. 42. As is illustrated, the barrier valley242 can be located on the connector engagement region 222, adjacent tothe panel engagement region 224, e.g., in contact therewith.

The various connectors, collectors, and assemblies disclosed hereinaddress the issue of needing expensive aluminum extrusions forconnectors. The present assemblies, utilizing various configurations(e.g., mechanical stops and/or extensions) to prevent panel separationcan provide enough strength to withstand hurricane force (e.g., 200 mph(322 kilometers per hour (kph)) winds with the use of plastic connectorand collectors, (or the side collectors when no connector is used). Thecombination of the profile structure and the clips that connects thepanels to support (e.g., rafter, etc.) has been modeled to provideenough strength to withstand these high loads.

Additionally, with the separate side collectors, substantial reductionin shipping costs can be attained. Since the panels do not include theside collectors, they can be packaged in a much smaller area, therebyallowing shipping of greater than or equal to 40% more product in thesame space.

The connectors, collectors, clips, and assemblies thereof as describedherein are further illustrated by the following non-limiting examples.

EXAMPLES Example 1

In this example, panels were tested on a 4 foot (ft) by 6 ft box (1.2meters (m) to 1.8 m) for the ability of the clips and panel assembliesto handle a load. A clip having the design illustrated in FIG. 38, witha flat cross-member was tested and compared to a clip having the designillustrated in FIG. 11 and a panel as illustrated in FIG. 12, with theheight of the extensions equal to 0.035 inches (0.889 millimeters (mm)).The panels as tested had a 5 wall X structure. Various configurationswere tested as shown in FIG. 30. Comparative Sample 1 (C1) was aconnector assembly having a 3 inch (in, 7.6 centimeters (cm)) centerbolt clip with a flat cross-member having the design illustrated in FIG.38; Comparative Sample 2 (C2) was the same as C1 but had a flush mount;Comparative Sample 3 (C3) was also the same as C1, but had a hanging ¾inch mount; and Comparative Sample 4 (C4) was also the same as C1, buthad a steel spacer. FIG. 30 illustrates the deflection (measured ininches) versus pressured (measured in pounds per square foot (lb/ft²))for the various clip designs and mount.

As can be seen from FIG. 30, it was surprising to discover that a liphaving a height of only 0.035 inch (0.889 mm) resulted in a substantialincrease in the ability of panels to handle a load. Specifically, theload increased from a maximum of 160 lb/ft² (7,656 Pa) before break forComparative Samples 1 to 4 (C1 to C4) without the lip to 325 lb/ft²(15,550 Pa) for Sample 1 having the lip as herein described. As shown inFIG. 30, Sample 1 did not break, i.e., the clip was able to preventpanel separation. For example, the ability of the panel to handle a loadwithout separation can be increased by greater than or equal to 25%,specifically, greater than or equal to 30%, more specifically, greaterthan or equal to 35%, even more specifically, greater than or equal to40%, and yet more specifically, greater than or equal to 50%.

Comparative Samples C5 and C6 illustrate further results of wind loadtesting where a panel with a connector assembly having the designillustrated in FIG. 29 was tested for wind load handling capabilitiesand compared to a panel having the connector assembly design illustratedin FIG. 38. A wind load of 200 mph (322 kph) is indicated by line 310 inFIG. 31. As can be seen from FIG. 31, at wind loads of greater than orequal to 200 mph (kph), Comparative Sample 5 (C5) and Comparative Sample6 (C6) had increasing deflection where C5 failed at a pressure of about180 lb/ft² (8,618 Pa) and C6 failed at a pressure of about 140 lb/ft²(6,703 Pa), where failing refers to the panel separation and/or clipbending. This example demonstrates that without the clip design with alip as described herein, the panel assemblies could separate and failunder wind loading greater than or equal to 200 mph (322 kph).

Example 2

In this example, panels having the connector assembly design illustratedin FIG. 38 and FIG. 12 were tested and compared at various wind loads.The panels as tested had a 5 wall X structure. Comparative Samples C7and C8 (FIG. 33) had the connector assembly design illustrated in FIG.38, while all the other samples in FIGS. 32, 34, and 35 had theconnector assembly design illustrated in FIG. 12. Table 1 lists the dataobserved from the wind load testing of Samples 2 to 5, while Table 2lists the data observed from the wind load testing of ComparativeSamples C7 and C8. Tables 3 and 4 list the data observed from the windload testing of Samples 6 to 11. FIGS. 32, 33, 34, and 35 graphicallyillustrate the results, with FIG. 33 belonging to the ComparativeSamples and FIGS. 32, 34, and 35 belonging to the samples having thedesign illustrated in FIG. 12. Wind speed is measured in mph anddeflection is measured in inches (in).

TABLE 1 Sample Data for 3 ft (0.9 m) Standing Seam Panel Sample No.Purlin Spacing Wind Load 2 3 ft, 0.9 m 152 mph, 244 kph 3 4 ft, 1.2 m138 mph, 222 kph 4 5 ft, 1.5 m 120 mph, 192 kph 5 6 ft, 1.8 120 mph, 192kph

TABLE 2 Comparative Sample Data for 2 ft (0.6 m) Wide Standing SeamPanel Sample No. Purlin Spacing Wind Load C7 3 ft, 0.9 m 215 mph, 346kph C8 5, 1.5 m 187 mph, 300 kph

The results in Table 2, specifically, C7 can be compared to Sample 10 inTable 4 and will be discussed in further detail. C7 had a larger battenand side collector than other samples, so it was able to sustain ahigher wind load than other samples because the larger batten and sidecollector added stiffness to the panel.

Table 3 lists the data from testing 4 foot (1.2 m) wide panels and FIG.34 illustrates the results. Samples 6 to 8 have the connector assemblyand clip design illustrated in FIG. 12. As can be seen from Table 3 andFIG. 34, as the purlin spacing increases, the wind speed and load thatthe connector assembly can resist is reduced. Additionally, the mode offailure changed from the samples tested in Table 2 compared to those inTables 1, 3 and 4. For example, the failure mode for the samples inTable 2 was due to the panel slipping off the clip, while the failuremode in Table 3 was due to failure of the clip, demonstrating that astronger clip can potentially allow for even high wind speeds to bewithstood than those tested. The failure mode for the samples in Table 1was tearing of the clip through the panel, which demonstrates themaximum load the panel can sustain.

TABLE 3 Data for 4 ft (1.2 m)Wide Panels Sample No. Purlin Spacing (ft)Deflection Type Wind Speed 6 4 Seam 99 mph, 160 kph 7 5 Seam 87 mph, 140kph 8 6 Seam 75 mph, 120 kph

Table 4 illustrates data for Samples 9 to 11, where Sample 9 had a fulllength, 18 foot (5.5 m) long clip and Samples 10 and 11 had a 3 inch(7.6 cm) long clip. Full length clip refers to a clip having the designillustrated in FIG. 11 and extending the full length of the panel, i.e.,18 feet (5.5 m), while the clip used in Samples 10 and 11 also have thedesign in FIG. 11, but had a length of 3 inches (7.6 cm). As can be seenin Table 4 and corresponding FIG. 35, the full clip can handle higherwind loads as compared to a clip having a length of 3 inches (7.6 cm).For example, the full clip (i.e., 18 foot (5.5 m)) can handle wind loadsgreater than or equal to 200 mph (322 kph), specifically greater than orequal to 225 mph (362 kph), and even more specifically, greater than orequal to 240 mph (386 kph) before failing, while the 3 inch (7.6 cm)clip can handle wind loads greater than or equal to 150 mph (240 kph),specifically, greater than or equal to 175 mph (282 kph), and even morespecifically, greater than or equal to 185 mph (298 kph).

TABLE 4 Data for 2 ft (0.6 m) Wide Standing Seam Panels Sample PurlinDeflection No. Spacing (ft) Clip Type Type Wind Speed 9 3 18 ft (5.5 m) Seam 240 mph, 386 kph 10 3 3 in (7.6 cm) Seam 187 mph, 300 kph 11 4 3 in(7.6 cm) Seam 194 mph, 312 kph

As mentioned, C7 in Table 2 can be compared to Sample 10 in Table 4. C7illustrates a higher load than that of Sample 10 because C7 had a battenand side collector, having the design illustrated in FIG. 28, that wastwice the size of the batten and side collector of Sample 10, having thedesign illustrated in FIG. 12. The larger batten and side collector sizeadded to the stiffness and load capacity of C7. Despite the increasedload, the failure mode of sliding off the clip showed that a higherpotential load can possibly be achieved through modification of the clipand panel interface. For example, in Sample 10, the failure mode wasfailure of the clip due to fracture, which is another indication that ahigher potential load can possible be obtained through a modification ofthe clip to a material with a higher strength. Comparing Sample 11 to C7and C8 demonstrates that the combination of strengthening the clip andcreating a mechanical stop at the interface between the panel and theclip can provide high wind load capability with a lower profile battenand side collector design. Sample 11 had a 4 foot purlin spacing andexceeded the results of Sample 10 with a 3 foot purling spacing. It canpossible for an assembly with the design of Sample 11 to have equivalentwind load handling capability with a batten and side collector designthat is half the size of that used in C7. For example, extrapolating theresults of Sample 11 to a 3 foot purlin spacing yields a value between210 and 250 mph, which would be approximately equal to that of C7.

It is contemplated that the connector assemblies disclosed herein can beused in the construction of naturally lit structures such asgreenhouses, pool enclosures, solar roof collectors (e.g., photovoltaicmodules), stadiums and sunrooms, glass panel roofs, and combinationscomprising at least one of the foregoing. For example, the connectorassemblies can be used to attach photovoltaic modules together.Photovoltaic modules are generally an assembly of the various componentsof the module, including a first layer, a fluid layer, a second layer,junction box, cables, micro-inverter, etc. (see FIG. 36 illustrating aphotovoltaic module 500). The connector assemblies described herein canbe used to hold photovoltaic modules together to create a solar panel. Amethod of making a solar panel is also contemplated where the method cancomprise attaching a photovoltaic module to another photovoltaic modulewith any of the designs of the connector assemblies described herein tocreate a solar panel.

The connector assemblies comprising the various designs of the clip witheither the lip or protrusion can be capable of withstanding a higherwind speed and load than connector assemblies with a clip having a flatcross-member. Such a design can enable the connector assemblies to beused in applications where high wind loads (e.g., greater than or equalto 200 mph (322 kph)) can be encountered.

In one embodiment, a connector assembly comprises: a connector; and apair of side collectors, each comprising a connector engagement regionhaving a size and geometry to mate with the connector so as to hold endsof two adjacent panels together; and a panel engagement regioncomprising a receiving area and having a size to attach onto an edge ofthe panel; and a clip, wherein the clip has a base that can be attachedto a support, an engagement, and a stem extending therebetween, whereinthe engagement has an extension projecting from a side of theengagement, wherein the panel engagement region further comprises anopening in a joint wall on a side of the panel engagement regionopposite the receiving area, wherein the opening is configured toreceive the extension of the engagement.

In one embodiment, a side collector comprises: a connector engagementregion comprising a head having a size and geometry to mate with a panelconnector; a panel engagement region comprising a receiving area havingan energy director extending into the receiving area, and having a sizeto attach onto an end of the panel; and a clip engagement regioncomprising an opening, and having a size to accommodate an extension ona side of an engagement of a clip.

In one embodiment, a panel assembly comprises: a connector assembly,comprising a connector; a pair of side collectors, each comprising aconnector engagement region; and a panel engagement region comprising areceiving area; and a clip, wherein the clip has a base that can beattached to a support, an engagement, and a stem extending therebetween,wherein the engagement has an extension protruding from a side of theclip, wherein the panel engagement region further comprises an openingin a joint wall on a side of the panel engagement region opposite thereceiving area, wherein the opening is configured to receive theextension of the engagement; a panel located in each panel engagementregion; and wherein the connector is mated with the connector engagementregion of the side collectors so as to hold ends of the panels together.

In one embodiment, a method of making a panel assembly, comprises:attaching a first panel to a second panel with a connector assembly,wherein the connector assembly comprises a connector; and a pair of sidecollectors, each comprising a connector engagement region having a sizeand geometry to mate with the connector so as to hold ends of twoadjacent panels together; and a panel engagement region comprising areceiving area and having a size to attach onto an edge of the panel;and a clip, wherein the clip has a base that can be attached to asupport, an engagement, and a stem extending therebetween, wherein theengagement has an extension projecting from a side of the engagement,wherein the panel engagement region further comprises an opening in ajoint wall on a side of the panel engagement region opposite thereceiving area, wherein the opening is configured to receive theextension of the engagement.

In one embodiment, a method of making a photovoltaic module assemblycomprises: attaching a first photovoltaic module to a secondphotovoltaic module with a connector assembly, wherein the connectorassembly comprises a connector; and a pair of side collectors, eachcomprising a connector engagement region having a size and geometry tomate with the connector so as to hold ends of two adjacent panelstogether; and a panel engagement region comprising a receiving area andhaving a size to attach onto an edge of the panel; and a clip, whereinthe clip has a base that can be attached to a support, an engagement,and a stem extending therebetween, wherein the engagement has anextension projecting from a side of the engagement, wherein the panelengagement region further comprises an opening in a joint wall on a sideof the panel engagement region opposite the receiving area, wherein theopening is configured to receive the extension of the engagement.

In one embodiment, an assembly comprises: a connector comprising twocavities defined by flexible walls, wherein each of the cavities has ageometry and is configured to mate with connector engagement regionsfrom a pair of side collectors; a header located between the twocavities; and a first slot on a side of the connector and between thecavities, wherein the first slot has a size and geometry to receive anend of a panel without a side collector, wherein the cavities enable twosets of panels to be stacked and connected with the connector; and aclip, wherein the clip has a base that can be attached to a support, anengagement, and a stem extending therebetween, wherein the stem divergesto a receiver located on an end of the stem opposite the base, whereinthe engagement has an extension projecting from a side of theengagement, wherein a panel engagement region on the side collectorscomprises an opening in a joint wall on a side of the panel engagementregion opposite a receiving area, wherein the opening is configured toreceive the extension of the engagement.

In the various embodiments, (i) the opening of the side collectorcomprises a complimentary geometry to the extension of the engagement,wherein the opening and the extension engage with one another and/or(ii) the extension penetrates into the opening of the panel engagementregion; and/or (iii) the base comprises elements that, when assembledwith the connector, collector, and panels, the panels will be level;and/or (iv) the base comprises a section formed by a side, area, and aleg, and wherein the side and leg have a length/that is greater than aheight of a fastener head, wherein the area extends from the side toanother side; and/or (v) the extension comprises a lip projecting from aside of the engagement and/or comprises a protrusion extending from aside of the engagement; and/or (vi) wherein adjacent panels areconnected by a mating geometry selected from the group consisting oftongue and groove and snap fit; and/or (vii) wherein adjacent panels areconnected by a lap joint; and/or (viii) a photovoltaic panel is locatedin the first slot; and/or (ix) the connector further comprises a secondslot on another side of the connector opposite the first slot andbetween the cavities, wherein the second slot has a size and geometry toreceive an end of another panel without a side collector; and/or (x)another photovoltaic panel is located in the second slot; and/or (xi)the clip further comprises members located on a receiver of the clip;and/or (xii) the header is configured to receive a connecting memberthat attaches the connector to members of the clip.

All ranges disclosed herein are inclusive of the endpoints, and theendpoints are independently combinable with each other (e.g., ranges of“up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, isinclusive of the endpoints and all intermediate values of the ranges of“5 wt. % to 25 wt. %,” etc.). “Combination” is inclusive of blends,mixtures, alloys, reaction products, and the like. Furthermore, theterms “first,” “second,” and the like, herein do not denote any order,quantity, or importance, but rather are used to denote one element fromanother. The terms “a” and “an” and “the” herein do not denote alimitation of quantity, and are to be construed to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context. The suffix “(s)” as used herein is intended toinclude both the singular and the plural of the term that it modifies,thereby including one or more of that term (e.g., the film(s) includesone or more films). Reference throughout the specification to “oneembodiment”, “another embodiment”, “an embodiment”, and so forth, meansthat a particular element (e.g., feature, structure, and/orcharacteristic) described in connection with the embodiment is includedin at least one embodiment described herein, and may or may not bepresent in other embodiments. In addition, it is to be understood thatthe described elements may be combined in any suitable manner in thevarious embodiments.

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

What is claimed is:
 1. A panel assembly, comprising: a connectorassembly, comprising a connector comprising two cavities defined byflexible walls, wherein each of the cavities has a geometry and isconfigured to mate with connector engagement regions from a pair of sidecollectors; a header located between the two cavities; and a first sloton a side of the connector and between the cavities, wherein the firstslot has a size and geometry to receive an end of a panel without a sidecollector, wherein the cavities enable two sets of panels to be stackedand connected with the connector; a pair of side collectors, eachcomprising a connector engagement region; and a panel engagement regioncomprising a receiving area and having a size to attach onto an edge ofa panel; and a clip, wherein the clip has a base that can be attached toa support, an engagement, and a stem extending therebetween, wherein theengagement has an extension protruding from a side of the engagementtoward the base, wherein the panel engagement region further comprisesan opening in a joint wall on a side of the panel engagement regionopposite the receiving area, wherein the opening is configured toreceive the extension of the engagement; a panel located in each panelengagement region; and wherein the connector is mated with the connectorengagement region of the side collectors so as to hold ends of thepanels together.
 2. The panel assembly of claim 1, wherein adjacentpanels are connected by a mating geometry selected from the groupconsisting of tongue and groove and snap fit.
 3. A method of making apanel assembly, comprising: attaching a first panel to a second panelwith a connector assembly, wherein the connector assembly comprises aconnector comprising two cavities defined by flexible walls, whereineach of the cavities has a geometry and is configured to mate withconnector engagement regions from a pair of side collectors; a headerlocated between the two cavities; and a first slot on a side of theconnector and between the cavities, wherein the first slot has a sizeand geometry to receive an end of a panel without a side collector,wherein the cavities enable two sets of panels to be stacked andconnected with the connector; and a pair of side collectors, eachcomprising a connector engagement region having a size and geometry tomate with the connector so as to hold ends of two adjacent panelstogether; and a panel engagement region comprising a receiving area andhaving a size to attach onto an edge of a panel; and a clip, wherein theclip has a base that can be attached to a support, an engagement, and astem extending therebetween, wherein the engagement has an extensionprojecting from a side of the engagement toward the base, wherein thepanel engagement region further comprises an opening in a joint wall ona side of the panel engagement region opposite the receiving area,wherein the opening is configured to receive the engagement.
 4. Themethod of claim 3, wherein the extension creates a mechanical stop whichprevents the first panel and second panel from separating from oneanother when exposed to a 200 mph wind load.
 5. The assembly of claim 3,wherein the extension comprises a lip.
 6. The method of claim 3, furthercomprising, penetrating into a side of the opening with the extension.7. The method of claim 3, wherein the side collectors further comprise ajoint side with an angled wall such that when assembled, the angledwalls form a space having a converging diameter from the base toward theconnector engagement region.
 8. An assembly, comprising: a connectorcomprising two cavities defined by flexible walls, wherein each of thecavities has a geometry and is configured to mate with connectorengagement regions from a pair of side collectors; a header locatedbetween the two cavities; and a first slot on a side of the connectorand between the cavities, wherein the first slot has a size and geometryto receive an end of a panel without a side collector, wherein thecavities enable two sets of panels to be stacked and connected with theconnector; and a clip, wherein the clip has a base that can be attachedto a support, a receiver, and a stem extending therebetween, wherein thestem diverges to the receiver which is located on an end of the stemopposite the base, the stem further comprises an engagement, wherein theengagement has an extension projecting from a side of the engagementtoward the base, wherein a panel engagement region on the sidecollectors comprises an opening in a joint wall on a side of the panelengagement region opposite a receiving area, wherein the opening isconfigured to receive the engagement.
 9. The assembly of claim 8,wherein a photovoltaic panel is located in the first slot.
 10. Theassembly of claim 8, wherein the connector further comprises a secondslot on another side of the connector opposite the first slot andbetween the cavities, wherein the second slot has a size and geometry toreceive an end of another panel without a side collector.
 11. Theassembly of claim 10, wherein another photovoltaic panel is located inthe second slot.
 12. The assembly of claim 8, wherein the clip furthercomprises members located on a receiver of the clip.
 13. The assembly ofclaim 8, wherein the header is configured to receive a connecting memberthat attaches the connector to members of the clip.
 14. The assembly ofclaim 8, wherein the extension creates a mechanical stop which preventsthe clip from detaching from the side collectors when exposed to a 200mph wind load.
 15. The assembly of claim 8, wherein at least one of theconnector, the side collectors, or the clip comprises a polymericmaterial.
 16. The assembly of claim 15, wherein the clip comprises apolymeric material.
 17. The assembly of claim 8, wherein the extensioncomprises a lip.
 18. The assembly of claim 8, wherein the extensiongrips the side collectors and prevents them from disassembling whenunder load.
 19. The assembly of claim 8, wherein the extension has twowalls extending from the engagement toward the base.